APRILIA PEGASO 650 - 1996 Owner's manual

Pegaso 650

use and maintenance

aprilia part# 8102759

2

use and maintenance Pegaso 650

First edition: december 1996

Reprint: january 2000

Produced and printed by:

editing division

Soave (VERONA) - Italy

Tel. +39 - 045 76 11 911

Fax +39 - 045 76 12 241

E-mail: [email protected]

www.stp.it

On behalf of:

aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - Italy

Tel. +39 - 041 58 29 111

Fax +39 - 041 44 10 54

www.aprilia.com

3!&%497!2.).'3

The following precautionary warnings are

used throughout this manual in order to

convey the following messages:

Safety warning. When you find this

symbol on the vehicle or in the

manual, be careful to the potential risk

of personal injury. Non-compliance with

the indications given in the messages

preceded by this symbol may result in

grave risks for your and other people’s

safety and for the vehicle!

Indications to make the opera-

tions easier. Technical informa-

tion.

4%#(.)#!,

The operations preceded by this

symbol must be repeated also on

the opposite side of the vehicle.

If not expressly indicated otherwise, for the

reassembly of the units repeat the disas-

sembly operations in reverse order.

The terms “right” and “left” are referred to

the rider seated on the vehicle in the nor-

mal riding position.

7!2.).'302%#!54)/.3

'%.%2!,!$6)#%

Before starting the engine, carefully read

this manual and in particular the section

“SAFE DRIVE”.

Your and other people’s safety depends

not only on your quickness of reflexes and

on your agility, but also on what you know

about the vehicle, on its efficiency and on

your knowledge of the basic information for

“SAFE DRIVE”. Therefore, get a thorough

knowledge of the vehicle, in such a way as

to be able to drive in the traffic safely.

a

c

(

use and maintenance Pegaso 650

3

This manual must be considered

as an integral part of the vehicle

and must always accompany it, even in

case of resale.

aprilia has carried out this manual with the

maximum attention, in order to supply the

user with correct and updated information.

However, since aprilia constantly im-

proves the design of its products, there

may be slight discrepancies between the

characteristics of your vehicle and those

described in this manual. For any clarifica-

tion concerning the information contained

in this manual, do not hesitate to contact

your aprilia Official Dealer.

For control and repair operations not ex-

pressly described in this publication, for the

purchase of aprilia genuine spare parts,

accessories and other products, as well as

for specific advice, contact exclusively

aprilia Official Dealers and Service Cent-

ers, which guarantee prompt and accurate

assistance.

Thank you for choosing aprilia. We wish

you a nice ride.

All rights as to electronic storage, repro-

duction and total or partial adaptation, with

any means, are reserved for all Countries.

In some countries the antipollution

and noise regulations in force re-

quire periodical inspections.

The user of the vehicle in these countries

must:

– contact an aprilia Authorized Dealer to

have the non-homologated components

replaced with others homologated for

use in the country in question;

– carry out the required periodical inspec-

tions.

When asking your Dealer for spare

parts, specify the spare parts code

indicated on the SPARE PARTS IDENTIFI-

CATION LABEL.

Write down the identification code in the

space here below, in order to remember it

also in case of loss or deterioration of the

label.

The label is positioned under the rider sad-

dle, stuck to the frame.

In this manual the various versions are in-

dicated by the following symbols:

cc

c

&

optional

2

catalytic version

VERSION:

I

Italy

V

Poland

U

United Kingdom

%

Israel

A

Austria

K

South Korea

P

Portugal

M

Malaysia

"

Finland

R

Chile

B

Belgium

Q

Bermuda

D

Germany

-

United States

of America

F

France

^

Australia

E

Spain

]

Brazil

G

Greece

°

South Africa

O

Holland

Î

New Zealand

C

Switzerland

[

Canada



Denmark

`

Croatia

J

Japan

Ñ

Slovenia

S

Singapore

4

use and maintenance Pegaso 650

4!",%/&#/.4%.43

SAFE DRIVE .....................................................................................................5

BASIC SAFETY RULES: ............................................................................6

CLOTHING .................................................................................................9

ACCESSORIES........................................................................................10

LOAD ........................................................................................................10

ARRANGEMENT OF THE MAIN ELEMENTS ...............................................12

ARRANGEMENT OF THE INSTRUMENTS ...................................................14

INSTRUMENTS AND INDICATORS ..............................................................14

INSTRUMENTS AND INDICATORS TABLE............................................15

MAIN INDEPENDENT CONTROLS ...............................................................16

CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR.......................16

CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ....................17

IGNITION SWITCH...................................................................................18

STEERING LOCK.....................................................................................18

AUXILIARY EQUIPMENT...............................................................................19

UNLOCKING/LOCKING THE SADDLE....................................................19

GLOVE/TOOL KIT COMPARTMENT.......................................................19

CRASH HELMET HOOK ..........................................................................20

ANTI-THEFT HOOK .................................................................................20

REAR LUGGAGE RACK ..........................................................................20

MAIN COMPONENTS.....................................................................................21

FUEL.........................................................................................................21

ENGINE OIL .............................................................................................21

BRAKE FLUID (recommendations) ..........................................................22

DISC BRAKES..........................................................................................22

FRONT BRAKE ........................................................................................23

REAR BRAKE...........................................................................................24

ADJUSTING THE REAR BRAKE .............................................................24

CLUTCH ...................................................................................................25

COOLANT ................................................................................................26

TYRES......................................................................................................27

EXHAUST SILENCERS

^

....................................................................28

CATALYTIC SILENCERS

2

.................................................................28

INSTRUCTIONS FOR USE.............................................................................29

PRELIMINARY CHECKING OPERATIONS.............................................29

STARTING................................................................................................30

DEPARTURE AND DRIVE .......................................................................32

RUNNING-IN ............................................................................................34

STOPPING ...............................................................................................34

PARKING..................................................................................................34

SUGGESTIONS TO PREVENT THEFT...................................................35

MAINTENANCE ..............................................................................................36

REGULAR SERVICE INTERVALS CHART .............................................36

IDENTIFICATION DATA...........................................................................37

AIR CLEANER..........................................................................................38

CHECKING THE ENGINE OIL LEVEL AND TOPPING UP .................... 39

CHANGING THE ENGINE OIL AND THE OIL FILTER........................... 40

FRONT WHEEL....................................................................................... 42

REAR WHEEL ......................................................................................... 44

CHAIN...................................................................................................... 46

REMOVING THE FUEL TANK................................................................. 48

REMOVING

THE RIGHT AND LEFT SIDES................................................................ 48

CHECKING THE STEERING................................................................... 49

CHECKING

THE REAR FORK FULCRUM AXIS ........................................................ 49

INSPECTING THE FRONT AND REAR SUSPENSIONS ....................... 49

REAR SUSPENSION............................................................................... 50

REAR SUSPENSION

WITH HYDRAULIC PRELOAD ADJUSTMENT

&

............................... 50

IDLING ADJUSTMENT............................................................................ 52

ADJUSTING THE ACCELERATOR CONTROL ...................................... 52

ADJUSTING THE COLD START CONTROL (

e

)................................... 52

SPARK PLUG .......................................................................................... 53

BATTERY................................................................................................. 54

CHECKING THE ELECTROLYTE LEVEL.............................................. 55

RECHARGING THE BATTERY ............................................................... 55

LONG INACTIVITY OF THE BATTERY ................................................. 55

CHANGING THE FUSES......................................................................... 56

CHECKING THE SIDE STAND AND THE SAFETY SWITCH ................ 57

ADJUSTING

THE HEADLIGHT BEAM ......................................................................... 58

BULBS ..................................................................................................... 58

CHANGING THE HEADLIGHT BULBS ................................................... 59

CHANGING THE REAR LIGHT BULB.................................................... 60

CHANGING THE FRONT DIRECTION INDICATOR BULBS.................. 60

CHANGING THE REAR DIRECTION INDICATOR BULBS .................... 61

CHANGING

THE NUMBER PLATE BULB................................................................... 61

TRANSPORT.................................................................................................. 62

DRAINING THE FUEL TANK................................................................... 62

CLEANING ..................................................................................................... 63

LONG PERIODS OF INACTIVITY........................................................... 64

TECHNICAL DATA ........................................................................................ 65

LUBRICANT TABLE ................................................................................ 68

Importers............................................................................................. 70-71

WIRING DIAGRAM - Pegaso 650............................................................ 72

WIRING DIAGRAM KEY - Pegaso 650 ................................................... 73

safe drive

6

use and maintenance Pegaso 650

"!3)#3!&%4925,%3

To drive the vehicle it is necessary to be in

possession of all the requirements pre-

scribed by law (driving licence, minimum

age, psychophysical ability, insurance,

state taxes, vehicle registration, number

plate, etc.).

Gradually get to know the vehicle by driv-

ing it first in areas with low traffic and/or pri-

vate areas.

The use of medicins, alcohol and drugs or

psychotropic substances notably increases

the risk of accidents.

Be sure that you are in good psychophysi-

cal conditions and fit for driving and pay

particular attention to physical weariness

and drowsiness.

Most road accidents are caused by the

driver’s lack of experience.

NEVER lend the vehicle to beginners and,

in any case, make sure that the driver has

all the requirements for driving.

7

use and maintenance Pegaso 650

Rigorously observe all road signs and na-

tional and local road regulations.

Avoid abrupt movements that can be dan-

gerous for yourself and other people (for

example: rearing up on the back wheel,

speeding, etc.), and give due consideration

to the road surface, visibility and other driv-

ing conditions.

Avoid obstacles that could damage the ve-

hicle or make you lose control.

Avoid riding in the slipstream created by

preceding vehicles in order to increase

your speed.

Always drive with both hands on the han-

dlebars and both feet on the footrests (or

on the rider’s footboards), in the correct

driving posture.

Avoid standing up or stretching your limbs

while driving.

8

use and maintenance Pegaso 650

COOLER

OIL

The driver should pay attention and avoid

distractions caused by people, things and

movements (never smoke, eat, drink, read,

etc.) while driving.

Use only the vehicle’s specific fuels and lu-

bricants indicated in the "LUBRICANT

CHART"; check the oil, fuel and coolant

levels regularly.

If the vehicle has been involved in an acci-

dent, make sure that no damage has oc-

curred to the control levers, pipes, wires,

braking system and vital parts.

If necessary, have the vehicle inspected by

an aprilia Official Dealer, who should care-

fully check the frame, handlebars, suspen-

sions, safety parts and all the devices that

you cannot check by yourself.

Always remember to report any malfunc-

tion to the technicians to help them in their

work.

Never use the vehicle when the amount of

damage it has suffered endangers your

safety.

9

use and maintenance Pegaso 650

ONLY ORIGINALS

Never change the position, inclination or

colour of: number plate, direction indica-

tors, lights and horns.

Any modification of the vehicle will result in

the invalidity of the guarantee.

Any modification of the vehicle and/or the

removal of original components can com-

promise vehicle performance levels and

safety or even make it illegal.

We recommend respecting all regulations

and national and local provisions regarding

the equipment of the vehicle.

In particular, avoid all modifications that in-

crease the vehicle’s performance levels or

alter its original characteristics.

Never race with other vehicles.

#,/4().'

Before starting, always wear a correctly

fastened crash helmet. Make sure that it is

homologated, in good shape, of the right

size and that the visor is clean.

Wear protective clothing, preferably in light

and/or reflecting colours. In this way you

will make yourself more visible to the other

drivers, thus notably reducing the risk of

being knocked down, and you will be more

protected in case of fall.

This clothing should be very tight-fitting

and fastened at the wrists and ankles.

Strings, belts and ties should not be hang-

ing loose; prevent these and other objects

from interfering with driving by getting en-

tangled with moving parts or driving mech-

anisms.

A12

345

10

use and maintenance Pegaso 650

Do not keep objects that can be dangerous

in case of fall, for example pointed objects

like keys, pens, glass vials etc. in your

pockets (the same recommendations also

apply to passengers).

!##%33/2)%3

The owner of the vehicle is responsible for

the choice, installation and use of any ac-

cessory.

Avoid installing accessories that cover

horns or lights or that could impair their

functions, limit the suspension stroke and

the steering angle, hamper the operation of

the controls and reduce the distance from

the ground and the angle of inclination in

turns.

Avoid using accessories that hamper ac-

cess to the controls, since this can prolong

reaction times during an emergency.

Large fairings and windscreens assembled

on the vehicle can produce aerodynamic

forces capable of compromising the stabili-

ty of the vehicle while driving.

Make sure that the equipment is well fas-

tened to the vehicle and not dangerous

during driving. Do not install electrical de-

vices and do not modify those already ex-

isting to avoid electrical overloads, be-

cause the vehicle could suddenly stop or

there could be a dangerous current short-

age in the horn and in the lights. aprilia

recommends the use of genuine accesso-

ries (aprilia genuine accessories).

,/!$

Be careful and moderate when loading

your luggage. Keep any luggage loaded as

close as possible to the centre of the vehi-

cle and distribute the load uniformly on

both sides, in order to reduce imbalance to

the minimum. Furthermore, make sure that

the load is firmly secured to the vehicle, es-

pecially during long trips.

11

use and maintenance Pegaso 650

KG!

Avoid hanging bulky, heavy and/or danger-

ous objects on the handlebars, mudguards

and forks, because the vehicle might re-

spond more slowly in turns and its ma-

noeuvrability could be unavoidably im-

paired.

Do not place bags that are too bulky on the

vehicle sides and do not ride with the crash

helmet hanging from its string, because it

could hit people or obstacles making you

lose control of the vehicle.

Do not carry any bag if it is not tightly se-

cured to the vehicle.

Do not carry bags which protrude too much

from the luggage rack or which cover the

lights, horn or indicators.

Do not carry animals or children on the

glove compartment or on the luggage rack.

Do not exceed the maximum load allowed

for each side-bag.

When the vehicle is overloaded, its stability

and its manoeuvrability can be compro-

mised.

12

use and maintenance Pegaso 650

!22!.'%-%.4/&4(%-!).%,%-%.43

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1) Ignition switch/steering lock

2) Fuel tank plug

3) Fuel cock

4) Battery

5) Fuses

6) Glove/tool kit compartment

7) Passenger grab rail

8) Rear luggage rack

9) Passenger footrest

10) Central stand

&

11) Side stand

12) Shifting lever

13) Expansion tank

13

use and maintenance Pegaso 650

+%9

1) Front brake master cylinder

2) Engine oil level plug-dipstick

3) Horn

4) Engine oil filter

5) Rear brake control lever

6) Anti-theft hook (for the aprilia “Body-

Guard” armored cable

&)

7) Rear brake master cylinder

8) Passenger footrest

9) Passenger grab rail

10) Saddle lock

11) Crash helmet hook

12) Rear brake fluid tank

13) Air cleaner

14

use and maintenance Pegaso 650

!22!.'%-%.4/&4(%).3425-%.43

+%9

1) Horn push button (

f)

2) Direction indicator switch (

c)

3) Dimmer switch (

b - a)

4) High beam signalling push button (

a)

5) Cold start lever (

e)

6) Clutch lever

7) Left rear-view mirror

8) Instruments and indicators

9) Right rear-view mirror

10) Front brake lever

11) Engine stop switch (

n - m)

12) Throttle grip

13) Light switch (o - p -

•

)

14) Start push button (

r)

15) Ignition switch/steering lock (

n - m - s)

).3425-%.43!.$).$)#!4/23

+%9

1) Green direction indicator warning light (

c)

2) Green neutral indicator warning light (

q)

3) Red engine oil pressure warning light (

j)

4) Blue high beam warning light (

a)

5) Green low beam and parking light warning light (

p)

6) Amber low fuel warning light (

g)

7) Revolution counter

8) Total kilometres odometer

9) Speedometer

9) Speedometer - only km/h scale

^

10) Coolant temperature indicator (h)

11) Partial kilometres odometer

12) Odometer trip control

15

use and maintenance Pegaso 650

).3425-%.43!.$).$)#!4/234!",%

Description Function

Direction indicator

warning light

c

It blinks when the direction indicators are on.

Neutral indicator warning light

q It comes on when the gear is in neutral.

Engine oil pressure

warning light

j

It comes on every time the ignition switch is brought to position "n" and the engine is not run-

ning, thus checking the proper functioning of the lamp. If during this phase the lamp does not

turn on, it must be replaced. The warning light must go off when the engine is running.

If the warning light comes on during the normal running of the engine, this

means that the oil pressure in the circuit is insufficient. In this case, immediate-

ly stop the engine and contact your APRILIA Official Dealer.

High beam warning light

a

It comes on when the headlight is in "high beam" position or when the high beam signalling is

operated.

Parking light

and low beam warning light

p

It comes on when the lights are on.

Low fuel warning light

g

It comes on when the quantity of fuel left in the tank is about 6 L (electrical reserve).

In this case, provide for immediate topping up, see p. 21 (FUEL).

Revolution counter

It indicates the number of revolutions of the engine per minute.

Never exceed the engine max. rpm, see p. 34 (RUNNING-IN).

Total kilometres odometer It indicates the total number of kilometres covered.

Speedometer It indicates the driving speed.

Coolant temperature indicator

h

It indicates the approximate temperature of the coolant in the engine. When the pointer starts

moving beyond level "40", the temperature is sufficient for driving the vehicle. The normal

running temperature range is indicated by the graduated area of the scale. If the pointer

reaches the red area, stop the engine and check the coolant level, see p. 26 (COOLANT).

If the maximum allowed temperature is exceeded (red area of the scale), the en-

gine may be seriously damaged.

Partial kilometres odometer It indicates the partial number of kilometres covered. To set it to zero, use the odometer trip control.

Odometer trip control Rotate it anticlockwise to set the partial kilometres odometer to zero.

a

16

use and maintenance Pegaso 650

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#/.42/,3/.4(%,%&43)$%/&4(%(!.$,%"!2

The electrical parts work only when the ignition

switch is in position "n".

1) HORN PUSH BUTTON (f)

The horn is activated when the push button is pressed.

2) DIRECTION INDICATOR SWITCH (

c)

To indicate the turn to the left, move the switch to the left; to

indicate the turn to the right, move the switch to the right. To

turn off the direction indicator, press the switch on its centre.

3) DIMMER SWITCH (b - a)

When the light switch (right side of the handlebar) is in posi-

tion "o", if the dimmer switch is in position "a", the high

beam comes on, while if it is in position "

b", the low beam

comes on.

4) HIGH BEAM SIGNALLING PUSH BUTTON (

a)

It makes it possible to use the high beam for signalling to

forthcoming vehicles while overtaking and in case of peril

and/or emergency.

5) COLD START LEVER (

e)

The starter for the cold start of the engine is operated by rotat-

ing the lever "e" downwards.

To disconnect the starter, move the lever "

e" to its initial po-

sition.

c

17

use and maintenance Pegaso 650

#/.42/,3/.4(%2)'(43)$%

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The electrical parts work only when the ignition

switch is in position "

n".

1) ENGINE STOP SWITCH (n - m)

Do not operate the engine stop switch “n - m” in

running conditions.

This is a safety or emergency switch.

With the switch in position "

n", it is possible to start the en-

gine; the engine can be stopped by moving the switch to posi-

tion "

m".

With stopped engine and ignition switch in posi-

tion "

n", the battery may discharge.

When the vehicle has come to rest, after stopping

the engine, move the ignition switch to position "m".

2) HEADLIGHT SWITCH (o - p -

•

)

When the light switch is in position "

•

", the lights are off; when

the switch is in position "

p", the parking lights are on; when

the switch is in position "

o", the low beam or the high beam is

on.

The high/low beam can be operated by means of the dimmer

switch, see p. 16 (CONTROLS ON THE LEFT SIDE OF THE

HANDLEBAR).

3) START PUSH BUTTON (

r)

When the start push button "

r" is pressed, the starter makes

the engine run. For the starting, see p. 30 (STARTING).

c

a

18

use and maintenance Pegaso 650

)'.)4)/.37)4#(

The ignition switch is positioned on the

steering column plate.

The key (1) operates the ignition

switch/steering lock, the saddle

lock and the fuel tank lock.

Two keys are supplied together with the

vehicle (one spare key).

34%%2).',/#+

Never turn the key to position "

s" in run-

ning conditions, in order to avoid losing

control of the vehicle.

OPERATION

To lock the steering:

U

Turn the handlebar completely leftwards.

U

Turn the key (1) to position “m” and

press it.

U

Release the key.

Turn the key and steer the han-

dlebar at the same time.

U

Rotate the key (1) anticlockwise (left-

wards), steer the handlebar slowly until

the key (1) reaches position “

s”.

U

Extract the key.

c

Position Function

Key

removal

Steering

lock

The steer-

ing is

locked.

It is neither

possible to

start the

engine, nor

to switch on

the lights.

It is possi-

ble to

remove the

key.

Neither the

engine, nor

the lights

can be

switched on.

It is possi-

ble to

remove the

key.

The engine

and the

lights can be

switched on.

It is not pos-

sible to

remove the

key.

19

use and maintenance Pegaso 650

!58),)!29%15)0-%.4

5.,/#+).',/#+).'

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U

Position the vehicle on the stand, see

p. 35 (POSITIONING THE VEHICLE ON

THE STAND).

U

Insert the key (1) in the saddle lock (2).

U

Turn the key (1) clockwise and raise and

remove the saddle.

Before lowering and locking the

saddle, make sure that you have

not left the key in the glove/tool kit com-

partment.

U

To lock the saddle, position the tang (3)

in its seat, then lower and press the sad-

dle, thus making the lock snap shut.

Before leaving, make sure that

the saddle is properly locked.

',/6%4//,+)4#/-0!24-%.4

The compartment is positioned under the

rear part of the saddle;

to reach it:

U

Unlock and raise the saddle.

The tool kit (4) includes:

– 3, 4, 5, 6, 8 mm Allen spanners

– 5,5-7 mm double fork spanner

– 8-11 mm double fork spanner

– 10-13 mm double fork spanner

– 19 mm simple fork spanner

– 24 mm simple fork spanner

– double-ended, cross-/cut-headed screw-

driver

– screwdriver handle

– 18 mm spark plug socket spanner

– socket spanner rod

– tool case

Max. allowed weight: 1.5 kg

c

a

20

use and maintenance Pegaso 650

#2!3((%,-%4(//+

Thanks to the crash helmet hook, you no

longer have to carry the crash helmet with

you every time you park the vehicle.

Do not ride with the crash helmet

hanging from the hook, as this

may seriously compromise your

safety.

To hang the crash helmet:

U

Raise the saddle.

U

Withdraw the eyelet (1) of the cable (2)

from the hook (3).

U

Pass the cable (2) through the visor

opening or through the apposite loop on

the crash helmet.

U

Insert the eyelet (1) completely in the

hook (3).

U

Lower the saddle and lock it.

!.4)4(%&4(//+

The anti-theft hook (4) is positioned on the

right side of the vehicle, near the rider’s

footboard.

To prevent the vehicle from being stolen, it

is advisable to secure it with the aprilia

“Body-Guard” armored cable

&

(5), avail-

able at any aprilia Official Dealer.

Do not use the hook to lift the ve-

hicle or for any purpose other

than securing the vehicle once it

has been parked.

2%!2,5''!'%2!#+

Max. allowed weight: 9 kg

a

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